Gas valve with electronic health monitoring

ABSTRACT

This disclosure relates generally to valves, and more particularly, to gas valve assemblies. In one illustrative but non-limiting example, a valve assembly may include a valve body, a valve situated in a fluid path of the valve body, a valve actuator for selectively moving the valve actuator, one or more sensors in communication with the fluid path, a controller secured relative to the valve body and in communication with the sensors, and memory operatively coupled to the controller. A user interface may be in communication with the memory and the controller and may be configured to receive a selection from a user for selecting one of two or more selectable options from the memory. The controller may compare sensed parameters to threshold values associated with the selected option. The user interface may have a lock on it to prevent tampering and to provide accountability.

This application is a continuation of co-pending U.S. patent applicationSer. No. 14/489,068, filed Sep. 17, 2014, and entitled “GAS VALVE WITHELECTRONIC HEALTH MONITORING”, which is incorporated herein byreference.

RELATED APPLICATIONS

This application is related to U.S. application Ser. No. 13/326,366filed Dec. 15, 2011 and entitled Gas Valve With Electronic Proof ofClosure System, U.S. application Ser. No. 13/326,353 filed Dec. 15, 2011and entitled Gas Valve With Electronic Valve Proving System, U.S.application Ser. No. 13/326,357 filed Dec. 15, 2011 and entitled GasValve with High/Low Gas Pressure Detection, U.S. application Ser. No.13/326,691 filed Dec. 15, 2011 and entitled Gas Valve With Fuel RateMonitor, U.S. application Ser. No. 13/326,355 filed Dec. 15, 2011 andentitled Gas Valve With Overpressure Diagnostics, U.S. application Ser.No. 13/326,358 filed on Dec. 15, 2011 and entitled Gas Valve With ValveLeakage Test, U.S. application Ser. No. 13/326,361 filed on Dec. 15,2011 and entitled Gas Valve With Electronic Cycle Counter, and U.S.application Ser. No. 13/326,523 filed on Dec. 15, 2011 and entitled GasValve With Communication Link, all of which are incorporated byreference in their entireties and for all purposes.

TECHNICAL FIELD

The disclosure relates generally to valves, and more particularly, togas valve assemblies.

BACKGROUND

Valves are commonly used in conjunction with many appliances forregulating the flow of fluid. For example, gas valves are oftenincorporated into gas-fired appliances to regulate the flow of gas to acombustion chamber or burner. Examples of such gas-fired appliances mayinclude, but are not limited to, water heaters, furnaces, boilers,fireplace inserts, stoves, ovens, dryers, grills, deep fryers, or anyother such device where gas control is desired. In such gas-firedappliances, the gas may be ignited by a pilot flame, electronic ignitionsource, or other ignition source, causing combustion of the gas at theburner element producing heat for the appliance. In many cases, inresponse to a control signal from a control device such as a thermostator other controller, the gas valve may be moved between a closedposition, which prevents gas flow, and an open position, which allowsgas flow. In some instances, the gas valve may be a modulating gasvalve, which allows gas to flow at one or more intermediate flow ratesbetween the fully open position and the fully closed position.Additionally or alternatively, valves are used in one or more otherapplications for controlling a flow (e.g., a flow of a fluid such as aliquid or gas, or a flow of other material).

SUMMARY

This disclosure relates generally to valves, and more particularly, togas valve assemblies. In one illustrative but non-limiting example, avalve assembly system may include a valve assembly and a user interface.A valve assembly may include a valve body having an inlet port and anoutlet port with a fluid path extending therebetween, a valve situatedin the fluid path, a valve actuator secured to the valve body, one ormore sensors in communication with the fluid path, a controller securedrelative to the valve body and in communication with the one or moresensors, and a memory secured relative to the valve body and operativelycoupled to the controller. The one or more sensors may sense one or moreparameters within the fluid path and the controller may determine one ormore valve conditions based on the one or more sense parameters bycomparing values related to the one or more sensed parameters to one ormore threshold values. The memory may store two or more selectableoptions, wherein each selectable option identifies correspondingthreshold values for the one or more threshold values. Once one or moreof the selectable options are selected, the controller may be configuredto use the one or more threshold values that correspond to the selectedselectable options when comparing values related to the one or moresensed parameters to the one or more threshold values.

In some illustrative instances, the valve assembly may include an inletport and an outlet port with a fluid path extending between the inletport and the outlet port, a valve situated in the fluid path, a valveactuator secured relative to the valve body, one or more local sensorsfor sensing one or more parameters of the valve, the valve actuator,and/or within the valve body, one or more remote sensor inputs, and acontroller secured relative to the valve body. The one or more remotesensor inputs may receive one or more sensed parameters from one or moreremotely located sensors located outside of the valve body, the valve,and the valve actuator. The controller may be in communication with theplurality of local sensors and the one or more remote sensor inputs, andthe controller may be configured to determine one or more valveconditions by comparing a value related to one or more of the sensedparameters of the plurality of local sensors and the sensed parametersfrom one or more remotely located sensors to one or more thresholdvalues.

In some illustrative instances, the memory of the valve assembly maystore one or more fixed thresholds and one or more adjustablethresholds, where the fixed thresholds may not be adjustable by users inthe field. The controller of the valve assembly may shut down the valveassembly if a value related to one or more of the sensed parametersexceed one or more of the fixed thresholds. If one or more valuesrelated to the sensed parameters exceed one or more of the adjustablethresholds, the controller may allow the valve assembly to continue tooperate, but may issue an alert.

In some instances, the valve assembly may operate by following a method.Illustratively, the method of operation may include receiving an inputrelated to a selection of one or more safety standards, wherein eachsafety standard may designate one or more thresholds. In theillustrative method, one or more parameters of the valve assembly may besensed and one or more values of the sensed parameters may betransferred to a controller of the valve assembly. The illustrativemethod may include using the controller of the valve assembly todetermine one or more valve conditions based on the one or more sensedparameters and the one or more thresholds designated by the selectedsafety standards. In some cases, an indication of the one or more valveconditions may be displayed on a user interface of a valve assemblysystem.

The preceding summary is provided to facilitate an understanding of someof the innovative features unique to the present disclosure and is notintended to be a full description. A full appreciation of the disclosurecan be gained by taking the entire specification, claims, drawings, andabstract as a whole.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure may be more completely understood in consideration of thefollowing detailed description of various illustrative embodiments inconnection with the accompanying drawings, in which:

FIG. 1 is a schematic perspective view of an illustrative fluid valveassembly;

FIG. 2 is a schematic first side view of the illustrative fluid valveassembly of FIG. 1;

FIG. 3 is a schematic second side view of the illustrative fluid valveassembly of FIG. 1, where the second side view is from a side oppositethe first side view;

FIG. 4 is a schematic input side view of the illustrative fluid valveassembly of FIG. 1;

FIG. 5 is a schematic output side view of the illustrative fluid valveassembly of FIG. 1;

FIG. 6 is a schematic top view of the illustrative fluid valve assemblyof FIG. 1;

FIG. 7 is a cross-sectional view of the illustrative fluid valveassembly of FIG. 1, taken along line 7-7 of FIG. 4;

FIG. 8 is a cross-sectional view of the illustrative fluid valveassembly of FIG. 1, taken along line 8-8 of FIG. 2;

FIG. 9 is a schematic diagram showing an illustrative fluid valveassembly in communication with a building control system and anappliance control system, where the fluid valve assembly includes adifferential pressure sensor connect to a valve controller;

FIG. 10 is a schematic diagram showing an illustrative fluid valveassembly in communication with a building control system and anappliance control system, where the fluid valve assembly includesmultiple pressure sensors connected to a valve controller;

FIG. 11 is a schematic diagram showing an illustrative schematic of alow gas pressure/high gas pressure limit control;

FIG. 12 is a schematic diagram showing an illustrative schematic valvecontrol and combustion appliance control, where the controls areconnected via a communication link;

FIG. 13 is a schematic diagram showing an illustrative valve control andproof of closure system in conjunction with a combustion appliance; and

FIGS. 14-17 are various illustrative schematic depictions of differentmethods for sensing a position and/or state of a valve within anillustrative valve assembly.

While the disclosure is amenable to various modifications andalternative forms, specifics thereof have been shown by way of examplein the drawings and will be described in detail. It should beunderstood, however, that the intention is not to limit aspects of thedisclosure to the particular illustrative embodiments described. On thecontrary, the intention is to cover all modifications, equivalents, andalternatives falling within the spirit and scope of the disclosure.

DESCRIPTION

The following description should be read with reference to the drawingswherein like reference numerals indicate like elements throughout theseveral views. The detailed description and drawings show severalillustrative embodiments which are meant to be illustrative of theclaimed disclosure.

Valve assemblies and/or valve assembly systems may include one or morevalves within a valve body, two or more valves in series, two or morevalves in parallel, and/or any other valve assembly configurationincluding at least one valve. The valve assemblies and valve assemblysystems disclosed herein may be used in any application in which a valvemay be utilized to assist in controlling a flow. Illustratively, valveassemblies and valve assembly systems may be utilized in control of fuelto a combustion device/system, flows in irrigation systems, flows forcommercial and home appliances, and/or other applications.

In one example, valve assemblies may be used with combustion appliances.Combustion appliances may be used to provide comfort (e.g., room heatingin commercial buildings, etc.) and/or to process heat (e.g., inindustrial sectors and other sectors). Because combustion appliances area key portion of any residential or industrial system, downtime due toan unexpected failure in a combustion appliance system may be costly.Thus, preventive maintenance that can be planned based on the health ofthe combustion appliance system and before a combustion appliance failsmay be preferred because it may eliminate unexpected failures and/orminimize the impact of downtime on the combustion appliance system.Downtime may be optimized if the maintenance of the combustion appliancesystem is planned based on actual real time system health indicators,rather than planning maintenance in fixed time intervals and/or apre-set schedule. Combustion appliance system components often do nothave an ability to monitor the health of the combustion appliance (orcomponents thereof) and thus, cannot provide data relevant forpreventive maintenance planning.

A valve with electronics and one or more sets of sensors may be capableof monitoring its health by observing various variable or parameters(e.g., diagnostic parameters) indicative of one or more valve statusand/or valve condition. Such variables and/or parameters may include,but are not limited to, total number of cycles of the valve (e.g., forON-OFF valves), totalized repositioning of a valve (e.g., for modulatingvalves), fluid pressure, temperature, leakage level detected during aValve Proving System test, leakage level detected during annual leaktesting, position of a safety valve when “closed”, particular gas levels(e.g., oxygen (O₂), carbon dioxide (CO₂), carbon monoxide (CO), and soon) in a connected flue or other location, fault history of the valve,time from the last maintenance, other variables and/or parameters,and/or any combination of the variables and/or parameters.Illustratively, as one or more monitored variables or parameters startto approach a threshold value (e.g., a threshold value set by a safetystandard, a threshold level set by a user, etc.), the valve assembly 10with or in communication with the one or more sensors may issue awarning to a user while maintaining operation of the combustionappliance system as long as the thresholds at a particular level are notexceeded.

In accordance with this disclosure, valves may be fitted to includeand/or communicate with sensors, switches, and/or other mechanical orelectronic devices to assist in monitoring and/or analyzing theoperation of the valve and/or connected appliance or system. The sensorsand/or switches may be of the electromechanical type, the electronictype, and/or of other types of sensors and/or switches, as desired. Akey (e.g., an electronic key) and/or a password may be required toaccess data and/or settings of the sensors and/or switches.

In some cases, a valve assembly 10 may be configured to monitor and/orcontrol various operations including, but not limited to, monitoringfluid flow and/or fluid consumption, electronic cycle counting,overpressure diagnostics, high pressure and low pressure detection,valve proving system tests, valve leakage tests, proof of valve closuretests, diagnostic communications, and/or any other suitable operation asdesired.

As referred to above, valves may be added to fluid path systemssupplying fuel and/or fluid to appliances (e.g., burners, etc.) or maybe used individually or in different systems. In some instances, gassafety shutoff valves may be utilized as automatic redundant valves.Redundancy is achieved, and often times required by regulatory agencies,by placing at least two safety shutoff valves in series. Theaforementioned redundant valves may be separate valves fitted togetherin the field and/or valves located together in a single valve body,these redundant valves are commonly referred to as double-block valves.Although safety shutoff valves are described in detail herein, thedisclosed concepts may be applied to other valve assemblyconfigurations, including valve assembly configurations with a singlevalve.

FIG. 1 is a schematic perspective view of an illustrative fluid (e.g.,gas, liquid, etc.) valve assembly 10 for controlling fluid flow to acombustion appliance or other similar or different device. In theillustrative embodiment, the gas valve assembly 10 may include a valvebody 12, which may generally be a six sided shape or may take on anyother shape as desired, and may be formed as a single body or may bemultiple pieces connected together. As shown, the valve body 12 maygenerally be a six-sided shape having a first end 12 a, a second end 12b, a top 12 c, a bottom 12 d, a back 12 e and a front 12 f, as depictedin the various views of FIGS. 1-6. The terms top, bottom, back, front,left, and right are relative terms used merely to aid in discussing thedrawings, and are not meant to be limiting in any manner.

The illustrative valve body 12 includes an inlet port 14, an outlet port16 and a fluid path or fluid channel 18 extending between the inlet port14 and the outlet port 16. Further, valve body 12 may include one ormore gas valve ports 20 (e.g., a first valve port 20 a and a secondvalve port 20 b, shown in FIGS. 7 and 8) positioned or situated in thefluid channel 18, one or more fuel or gas valve member(s) sometimesreferred to as valve sealing member(s) 22 moveable within gas valveports 20 (e.g., a first valve sealing member 22 a within first valveport 20 a and a second valve sealing member 22 b within second valveport 20 b, as shown in FIG. 7), one or more pressure sensor assemblies24 (as shown in FIG. 8, for example), one or more position sensors 48,and/or one or more valve controllers 26 (as shown in FIG. 8, forexample) affixed relative to or coupled to the valve body 12 and/or inelectrical communication (e.g., through a wired or wireless connection)with the pressure sensor assemblies 24 and the position sensor(s) 48.

The valve assembly 10 may further include one or more actuators foroperating moving parts therein. For example, the valve assembly 10 mayhave actuators including, but not limited to, one or more stepper motors94 (shown as extending downward from bottom 12 d of valve body 12 inFIG. 1), one or more solenoids 96 (shown as extending upward from top 12c of valve body 12 in FIG. 1), and one or more servo valves 98 (a servovalve 98 is shown as extending upward from top 12 c of valve body 12 inFIG. 1-3, where a second servo valve has been omitted), where the servovalve 98 may be a 3-way auto-servo valve or may be any other type ofservo valve. Other actuators may be utilized, as desired.

In one illustrative embodiment, the one or more solenoids 96 may controlwhether the one or more gas valve ports 20 are open or closed. The oneor more stepper motors 94 may determine the opening size of the gasvalve ports 20 when the corresponding gas valve sealing member 22 isopened by the corresponding solenoid 96. Of course, the one or morestepper motors 94 may not be provided when, for example, the valveassembly 10 is not a “modulating” valve that allows more than oneselectable flow rate to flow through the valve when the valve is open.

As shown, the valve body 12 may include one or more sensors andelectronics compartments 56, which in the illustrative embodiment,extend from back side 12 e as depicted in FIGS. 1, 2 and 4-6. Thesensors and electronics compartments 56 may be coupled to or may beformed integrally with the valve body 12, and may enclose and/or containat least a portion of the valve controllers 26, the pressure sensorsassemblies 24, and/or the electronics required for operation of valveassembly 10 as described herein. Although the compartments 56 may beillustratively depicted as separate structures, the compartments 56 maybe a single structure part of, extending from, and/or coupled to thevalve body 12.

The one or more fluid valve ports 20 may include a first gas valve port20 a and a second gas valve port 20 b situated along and/or incommunication with the fluid channel 18. This is a double-block valvedesign. Within each gas valve port 20, a gas valve sealing member 22 maybe situated in fluid channel 18 and may be positioned (e.g.,concentrically or otherwise) about an axis, rotatable about the axis,longitudinally and axially translatable, rotationally translatable,and/or otherwise selectively movable between a first position (e.g., anopen or closed position) and a second position (e.g., a closed or openposition) within the corresponding valve port 20. Movement of the valvesealing member 22 may open and close the valve port 20.

It is contemplated that valve sealing member 22 may include one or moreof a valve disk 91, a valve stem 92 and/or valve seal 93 for sealingagainst a valve seat 32 situated in fluid channel 18, as best seen inFIGS. 14-17, and/or other similar or dissimilar components facilitatinga seal. Alternatively, or in addition, valve sealing member 22 mayinclude structural features and/or components of a gate valve, adisk-on-seat valve, a ball valve, a butterfly valve and/or any othertype of valve configured to operate from a closed position to an openposition and back to a closed position. An open position of a valvesealing member 22 may be any position that allows fluid to flow throughthe respective gas valve port 20 in which the valve sealing member 22 issituated, and a closed position may be when the valve sealing member 22forms at least a partial seal at the respective valve port 20, such asshown in FIG. 7. Valve sealing member 22 may be operated through anytechnique. For example, valve sealing member 22 may be operated throughutilizing a spring 31, an actuator 30 to effect movement against thespring 31, and in some cases a position sensor 48 to sense a position ofthe valve sealing member 22.

Valve actuator(s) 30 may be any type of actuator configured to operatethe valve sealing member 22 by actuating valve sealing member 22 fromthe closed position to an open position and then back to the closedposition during each of a plurality of operation cycles during alifetime of the gas valve assembly 10 and/or of the actuator 30. In somecases, the valve actuator 30 may be a solenoid actuator (e.g., a firstvalve actuator 30 a and a second valve actuator 30 b, as seen in FIG.7), a hydraulic actuator, magnetic actuators, electric motors, pneumaticactuators, and/or other similar or different types of actuators, asdesired. In the example shown, the valve actuators 30 a, 30 b may beconfigured to selectively move valves or valve sealing members 22 a, 22b of valve ports 20 a, 20 b between a closed position, which closes thefluid channel 18 between the inlet port 14 and the outlet port 16 of thevalve body 12, and an open position. As discussed, the gas valveassembly 10 of FIGS. 1-8 is an example of a gas safety shutoff valve, ordouble-block valve. In some cases, however, it is contemplated that thegas valve assembly 10 may have a single valve sealing member 22 a, orthree or more valve sealing members 22 in series or parallel, asdesired.

In some cases, the valve assembly 10 may include a characterized portdefined between the inlet port 14 and the outlet port 16. Acharacterized port may be any port (e.g., a fluid valve port 20 or otherport or restriction through which the fluid channel 18 may travel) at oracross which an analysis may be performed on a fluid flowingtherethrough. For example, if a flow resistance of a valve port 20 isknown over a range of travel of the valve sealing member 22, the one ofthe one or more gas valve ports 20 may be considered the characterizedport. As such, and in some cases, the characterized port may be a port20 having the valve sealing member 22 configured to be in an openposition and in a closed position. Alternatively, or in addition, acharacterized port may not correspond to the gas valve port 20 havingthe valve sealing member 22. Rather, the characterized port may be anyconstriction or feature across which a pressure drop may be measuredand/or a flow rate may be determined.

Characterized ports may be characterized at various flow rates toidentify a relationship between a pressure drop across the characterizedport and the flow rate through the fluid channel 18. In some cases, thepressure drop may be measured directly with one or more pressure sensors42, 43, 44, and/or 38. In other cases, the pressure drop may be inferredfrom, for example, the current position of the valve member(s). Theseare just some examples. In some cases, the relationship may be stored ina memory 37, such as a RAM, ROM, EEPROM, other volatile or non-volatilememory, or any other suitable memory of the gas valve assembly 10, butthis is not required.

In some cases, the gas valve assembly 10 may include a flow module 28for sensing one or more parameters of a fluid flowing through fluidchannel 18, and in some instances, determining a measure related to agas flow rate of the fluid flowing through the fluid channel 18. Theflow module 28 may include a pressure block or pressure sensor assembly24, a temperature sensor 34, a valve member position sensor 48 and/or avalve controller 26, among other assemblies, sensors, and/or systems forsensing, monitoring, and/or analyzing parameters of a fluid flowingthrough the fluid channel 18, such as can be seen in FIGS. 9 and 10.

It is contemplated that the flow module 28 may utilize any type ofsensor to facilitate determining a measure related to a flow rate of afluid through fluid channel 18, such as a pressure sensor, a flowsensor, a valve position sensor, a temperature sensor, a current sensor,a gas sensor, an oxygen sensor, a CO sensor, a CO₂ sensor, and/or anyother type of sensor, as desired. In one example, the flow module 28,which in some cases may be part of a valve controller 26, may beconfigured to monitor a differential pressure across a characterizedport, and in some cases, a position of one or more valve sealing members22 of the gas valve assembly 10. The information from monitoring may beutilized by the flow module 28 to determine and/or monitor the flow rateof fluid passing through the fluid channel 18. For example, the flowmodule 28 may determine a measure that is related to a gas flow ratethrough the fluid channel 18 based, at least in part, on the measurethat is related to the pressure drop across the characterized port alongwith the pre-stored relationship in the memory 37. In some cases, thecurrent position of one or more valve sealing members 22 of the gasvalve assembly 10 may also be taken into account (e.g. is the valve 30%open, 50% open or 75% open).

In some instances, the flow module 28 may be configured to output theflow rate of fluid passing through the fluid channel 18 to a display ora remote device. In some cases, the flow module 28 may maintain acumulative gas flow amount passing through the fluid channel 18 (e.g.over a time period), if desired. The measure related to a gas flow mayinclude, but is not limited to, a measure of fuel consumption by adevice or appliance that is connected to an outlet port 16 of the gasvalve assembly 10.

It is contemplated that the valve controller or valve control block 26(see, FIG. 8-10) may be physically secured or coupled to, or secured orcoupled relative to, the valve body 12. The valve controller 26 may beconfigured to control and/or monitor a position or state (e.g., an openposition and a closed position) of the valve sealing members 22 of thevalve ports 20 and/or to perform other functions and analyses, asdesired. In some cases, the valve control block 26 may be configured toclose or open the gas valve member(s) or valve sealing member(s) 22 onits own volition, in response to control signals from other systems(e.g., a system level or central building control), and/or in responseto received measures related to sensed pressures upstream, intermediate,and/or downstream of the characterized valve port(s), measures relatedto a sensed differential pressure across the characterized valveport(s), measures related to temperature sensed upstream, intermediate,and/or downstream of the characterized valve port(s), and/or in responseto other measures, as desired.

The memory 37, which in some cases may be part of or in communicationwith the valve controller 26, may be configured to include systemsettings and record data related to sensed pressures, senseddifferential pressures, sensed temperatures, and/or other measures. Thevalve controller 26 may access these settings and this data, and in somecases, communicate (e.g., through a wired or wireless communication link100) the data and/or analyses of the data to other systems (e.g., asystem level or central building control) as seen in FIGS. 9 and 10. Thememory 37 and/or other memory may be programmed and/or developed tocontain software to affect one or more of the configurations describedherein.

In some instances, the valve controller 26 may be considered a portionof the flow module 28, the flow module 28 may be considered part of thevalve controller 26, or the flow module 28 and valve controller 26 maybe considered separate systems or devices. Illustratively, the valvecontroller 26 may be coupled relative to the valve body 12 and one ormore gas valve ports 20, where the valve controller 26 may be configuredto control a position (e.g., open or closed positions, including variousopen positions) of the valve sealing member 22 within the valve port 20.In some cases, the valve controller 26 may be coupled to and/or be incommunication with local sensors including, but not limited to thepressure sensor assembly 24 (e.g., used for Low Gas/High Gas pressurelimit functions, Valve Proving System tests, etc.), a flow sensor (e.g.,for measuring gas consumption, etc.), a temperature sensor, 34 (e.g., tomonitor temperature of a key component such as an actuator or othercomponent, etc.), a position sensor 48, a current draw sensor (e.g., forsensing the current draw of an actuator or the entire system, etc.), agas sensor, an oxygen sensor, a carbon monoxide (CO) sensor, a carbondioxide (CO₂) sensor, a cycle sensor and/or cycle counter, timers (e.g.,to measure an amount of time to open the valve and/or close the valve),and/or other sensors and assemblies, as desired.

The valve controller 26 may include or may be in communication with oneor more remote sensor inputs for receiving one or more sensed parametersform one or more remotely located sensors located outside of the valvebody 12, the valve ports 20, and/or valve actuators 30. Illustratively,the one or more remote sensors may include, but are not limited to, oneor more of a pressure sensor, a flow sensor, a temperature sensor, aposition sensor, a current draw sensor, a gas sensor, an oxygen sensor,a carbon monoxide (CO) sensor, a carbon dioxide (CO₂) sensor, a cyclesensor and/or cycle counter, and/or one or more other remote sensors.

In the illustrative embodiment of FIG. 8, the valve controller 26 may beconfigured to monitor a differential pressure across a characterizedport. In some instances, the valve controller 26 may monitor adifferential pressure across the fluid valve port 20 and/or monitor ameasure related to a pressure upstream of a fluid valve port 20 (e.g.,first valve port 20 a) and/or a measure related to a pressure downstreamof a fluid valve port 20 (e.g., second valve port 20 b). The valvecontroller 26 may also be configured to monitor an axial position of thevalve sealing member 22 in the valve port 20 (e.g., see FIGS. 14-17). Asa result, the valve controller 26 may determine a flow rate of fluidpassing through the characterized port, where the valve controller 26may determine the flow rate (and sometimes fluid consumption) based, atleast in part, on the monitored differential pressure and/or monitoredupstream and downstream pressures in conjunction with apre-characterized relationship between the pressure drop across thecharacterized port and the flow rate. In some cases, the monitored axialpositioning of the valve sealing member 22 may also be taken intoaccount, particularly when the valve sealing member 22 may assume one ormore intermediate open positions between the fully closed and fullyopened positions. When so provided, the pre-characterized relationshipbetween the pressure drop across the characterized port and the flowrate may depend on the current axial positioning of valve sealing member22.

In some instances, the valve controller 26 may include a determiningblock, which may include a microcontroller 36 or the like, which mayinclude or be in communication with a memory 37, such as a non-volatilememory. Alternatively, or in addition, the determining block (e.g.microcontroller 36) may be coupled to or may be configured within thevalve control block or valve controller 26. The determining block may beconfigured to store and/or monitor one or more parameters, which may beused when determining a measure that is related to a fluid flow ratethrough the fluid channel 18. The determining block (e.g.microcontroller 36) may be configured to use the stored and/or monitoredparameters (e.g. the relationship between a pressure drop across acharacterized port and the flow rate through the fluid channel 18)stored in the memory 37 to help determine a measure that is related to afluid flow rate through the fluid path or the fluid channel 18.

Illustratively, the determining block (e.g. microcontroller 36) may beconfigured to determine and/or monitor a measure (e.g., a flow rate offluid passing through the characterized port or other similar ordifferent measure, as desired) based, at least in part, on stored and/ormonitored measures including, but not limited to, measures related topressure drop across a characterized valve port or other pressurerelated measures upstream and downstream of the characterized valveport(s), a temperature of the fluid flowing through the fluid channel18, and/or a measure related to a current position of the valve sealingmember 22 at the gas valve port 20 or the size of an opening at thecharacterized port. In one example, a determining block (e.g.microcontroller 36) may include non-volatile memory that is configuredto store opening curves of the valve assembly 10, where the openingcurves may characterize, at least in part, a flow rate as a function ofa sensed axial position of valve sealing member 22, and a senseddifferential pressure across a characterized valve port 20 or anotherwise determined pressure at or adjacent a characterized valve port20 (e.g., knowing a set-point of an upstream pneumatic pressure reducingvalve (PRV), as the set-point pressure of the PRV may be substantiallyequal to the pressure at an inlet of the characterized valve port), andmay facilitate determining an instantaneous and/or cumulative fluid(e.g., fuel) flow in the fluid channel 18 and/or consumption by anappliance in fluid communication with the valve assembly 10.

It is contemplated that the determining block (e.g. microcontroller 36)may continuously or non-continuously control, store, and/or monitor aposition (e.g., an axial or rotary position or open/closed state orother position) of the valve sealing member 22 within the valve port 20,monitor a differential pressure across the characterized port, and/ormonitor a temperature upstream and/or downstream of the characterizedport. In addition, the microcontroller 36 may continuously ornon-continuously determine the flow rate of the fluid passing throughthe characterized port, where the microcontroller 36 may be configuredto record in its memory or in another location, an instantaneous flowrate of fluid flowing through the characterized port, a cumulative flowvolume, and/or a determined instantaneous or cumulative (e.g., total)fluid consumption based on the positions of the valve sealing member(s)22 and determined flow rates at an instant of time or over a specifiedor desired time period. In addition, the determining block (e.g.microcontroller 36) may be configured to report out the instantaneousflow rate, cumulative flow volume, total or cumulative fluid consumptionover a given time period, and/or other determination and/or valveassembly conditions. The determining block (e.g. microcontroller 36) mayreport the instantaneous flow rate, cumulative flow rate, total orcumulative consumption of the fluid flowing through the characterizedport, and/or other determination and/or valve assembly conditions to asystem display 52 of an overall system controller 50 (e.g., abuilding/industrial automation system (BAS/IAS) controller), anappliance display 62 of an appliance/system controller 60 where theappliance may be configured to receive the flowing fluid, a displayadjacent gas valve assembly 10, or any other display 77, device,controller and/or memory, as desired.

In some instances, the valve controller 26 may include or be incommunication with a valve actuator 30, which in conjunction with thestepper motor 94 or other device is configured to position the valvesealing member 22 in the valve port 20. The valve actuator 30 and/or thestepper motor 94 may be in communication with the microcontroller 36 ofthe valve controller 26, and the microcontroller 36 may be configured tocontrol, monitor, and/or record the position (e.g., axial position,radial position, etc.) of the valve sealing member 22 within the valveport 20 through the valve actuator 30 (e.g., the valve actuator 30 maybe configured to effect the locking (e.g., the valve actuator 30 OFF) orthe unlocking (e.g., the valve actuator 30 ON) of the valve sealingmember 22 in a particular position) and the stepper motor 94 (e.g.,stepper motor 94 may be configured to adjust the position of the valvesealing member 22 when it is not locked in a particular position), orthrough only the stepper motor 94. Alternatively, or in addition, themicrocontroller 36 may be configured to monitor and record the positionof the valve sealing member 22 within the valve port 20 through aconnection with a position sensor 48 or through other means.

The valve controller 26 may include an I/O or communications interface110 with a communication protocol for transmitting data to and/orotherwise communicating with one or more remote device(s) that may belocated remotely from valve assembly 10 (e.g., a combustion applianceincluding controller 60 located remotely from valve assembly 10, aremote display 77, an electronic access tool or key 79, and/or otherremote devices). The communications interface 110 may be a wired orwireless communication interface, where the wired or wirelesscommunication interface 110 may be configured to be compatible with apredetermined communication bus protocol or other communicationprotocol. A wired link may be low voltage (e.g. 24V, 5V, 3V, etc.),which may reduce certain issues related to line-voltage wiring schemes.Illustratively, communications interface 110, using the predeterminedcommunication bus protocol or other communication protocol, may beconfigured to output and/or communicate one or more valve conditions,one or more measures related to valve conditions, one or more conditionsrelated to a fluid flow through the fluid channel 18, and/or one or morediagnostic parameters, conditions or events, to a device locatedadjacent or remote from the valve assembly 10.

In an illustrative example of monitoring parameters sensed by sensors ofor in communication with a valve assembly, the microcontroller 36 of thevalve controller 26 may continuously or non-continuously monitor andrecord the position (e.g., axial position, radial position, etc.) ofvalve sealing member 22 within the valve port 20 through the valveactuator 30 and the stepper motor 94, and the microcontroller 36 mayindicate the sensed and/or monitored position of the valve sealingmember 22 within the valve port 20 as a prescribed position of valvesealing member 22. The prescribed position of the valve sealing member22 may be the position at which the valve sealing member 22 was and/oris to be located, whereas a position of the valve sealing member 22sensed by the position sensor system 48 may be considered an actualposition of the valve sealing member 22 within the valve port 20.

In the example, the valve controller 26 may be configured to performelectronic operational cycle counting or may include an electroniccounter configured to count each operational valve cycle of the valvesealing members 22 during, for example, the lifetime of the gas valveassembly 10 or during some other time period. In some cases, themicroprocessor 36 of the valve controller 26 may be configured tomonitor a total number of operational cycles (e.g., the number of timesthe fuel valve sealing members 22 are operated from a closed position toan open position and back to a closed position) of the valve ports 20and measures related thereto. In some cases, the microprocessor 36 maystore such data in a non-volatile memory, such as the memory 37,sometimes in a tamper proof manner, for record keeping and/or otherpurposes. The microprocessor 36 may monitor the number of cycles of thevalve sealing members 22 in one or more of several different manners.For example, the microprocessor 36 may monitor the number of cycles ofthe valve sealing members 22 by monitoring the number of times the firstmain valve switch 72 and/or the second main valve switch 74 are poweredor, where one or more control signals may be provided to the fuel valveactuator(s) 30 controlling when the fuel valve actuator(s) 30selectively moves (e.g., opens or closes) the valve sealing member(s)22, the microprocessor 36 may monitor the one or more control signals.

The valve controller 26, in some cases, may monitor the main valveswitches 72, 74 by receiving signals directly from a device locatedremotely from the valve assembly 10 on which the main valve switches 72,74 may be located (e.g. see FIGS. 11-12). Switches ((main valve switches72, 74 and safety switch 70 (discussed below)) may be any mechanismcapable of performing a switching function including, but not limitedto, relays, transistors and/or other solid state switches and circuitdevices and/or other switches. The valve controller 26 may include anelectrical port, sometimes separate from a communications interface 110(discussed below), for receiving one or more control signals from thedevice located remotely from valve assembly 10. The one or more controlsignals received via the electrical port may include, but are notlimited to: a first valve port 20 a control signal that, at least inpart, may control the position of the first valve sealing member 22 avia the first valve actuator 30 a, and a second valve port 20 b controlsignal that, at least in part, may control the position of the secondvalve sealing member 22 b via the second valve actuator 30 b.

As an alternative to monitoring control signals, or in addition,microprocessor 36 may monitor the number of cycles of valve sealingmembers 22 by monitoring data from a position sensor 48. For example,microprocessor 36 of valve controller 26 may monitor position sensor 48and record the number of times valve sealing members 22 are in an openposition after being in a closed position and/or the number of timesvalve sealing members 22 are in a closed position after being in an openposition and/or the number of times valve sealing members are operatedfrom a close position to an open position and back to a closed position.These are just some examples. Further, if valve controller 26 isoperating valve sealing members 22, valve controller 26 may monitor thenumber of operational cycles by counting its own control signals sent tovalve actuators 30 and/or stepper motors 94.

The non-volatile memory, which may maintain and/or store the number ofoperational valve cycles, may be positioned directly on, or packagedwith, valve body 12 (e.g., on or within memory of microcontroller 36)and/or may be accessible by the valve controller 26. Such storage,placement, and/or packaging of valve cycle data may allow forreplacement of components in the overall system (e.g., an appliancecontrol 60, etc.) without losing the valve cycle data. In anillustrative instance, the valve cycle data may be securely stored, suchthat it may not be tampered with. For example, the valve cycle data maybe stored in the memory 37 (e.g., non-volatile memory or other memory)of the valve controller 26 and the valve cycle data and/or other valveassembly 10 data may be password protected.

The microcontroller 36 of valve assembly 10 may be configured to comparea count of a total number of operational cycles of valve sealing members22 to a threshold number of operational cycles. In an instance where thecounted number of operational cycles of the valve sealing member(s) 22 tapproaches, meets, or exceeds the threshold number of cycles, themicrocontroller 36 may initiate a warning and/or request a switch 69 ina limit string 67 to open and thus, remove or cut power to the valveswitches 72, 74 and fuel valve actuator(s) 30. Alternatively, or inaddition, the microcontroller 36 may send a signal to initiate an alarmand/or put the system in a safety lockout, or the microcontroller 36 maybe configured to take other action as desired. Illustratively, themicrocontroller 36 may be configured to prevent fuel valve actuator(s)30 from allowing the valve sealing member(s) 22 to open after the totalnumber of operational cycles meets and/or exceeds the threshold numberof operational cycles. In some instances, the threshold number of cyclesmay be related to the number of cycles for which the valve assembly 10is rated (e.g., a maximum number of cycles before failures might beexpected, etc.) or related to any other benchmark value. In addition,the microcontroller 36 may be configured to perform other diagnosticsbased on analyzing captured operational cycle data, where the otherdiagnostics may include number of cycles, time duration of cycles, andsimilar or different diagnostics, as desired.

In addition to the communication interface 110 being configured tooutput information to a device located adjacent or remote from the valveassembly 10, the communication interface 110 may be configured toreceive one or more inputs from the remote device or an adjacentlypositioned device. Illustrative inputs may include, but are not limitedto: an acknowledgement of reception of one or more of the valveconditions, a user setting, a system setting, a valve command, and/orother similar or dissimilar input.

In some instances, the valve controller 26 may communicate through theI/O interface or communication interface 110 with a remotely locatedoutput block 46, where the output block 46 may display and/or output adetermined measure related to fluid flow rate through the fluid channel18, sometimes along with other data, information and controls sent fromthe valve controller 26 (see, for example, FIGS. 9 and 10). The outputblock 46 may include a display and/or other remote systems, and themicrocontroller 36 may be configured to send measures to a devicecontrol system 60 or building automation system or overall systemcontroller 50 of the output block 46 for further monitoring and/oranalysis. As discussed, the I/O interface may include a wired and/orwireless interface between the valve controller 26 (e.g.,microcontroller 36) and the output block 46 systems (e.g., the buildingautomation system or the overall system controller 50, the combustionappliance management system 60, handheld device, laptop computer, smartphone, etc.), where the connection between the valve controller 26 mayor may not be made with the communication link 100 (e.g., thecommunication link 100 could, but need not be, the one and only onecommunication link).

In an illustrative operation, the valve controller 26 may be utilized ina method for communicating information between the valve assembly 10 anda combustion appliance controller 60, where the combustion appliancecontroller 60 may be associated with a combustion appliance (e.g., adevice separate from, and possibly remotely relative to valve assembly10) for which the valve assembly 10 may control a flow of fuel. Theoperation may include sensing, with one or more sensor (e.g., pressuresensor assembly 24), one or more sensed parameters within the fluidchannel 18 of the valve assembly 10. The sensed parameter may be storedin the memory 37 (e.g., non-volatile memory or other memory) of thevalve controller 26. The valve controller 26 may determine one or morevalve conditions (e.g., a safety event condition or other valvecondition) based on the one or more sensed parameters. For example, thevalve controller 26 may compare one or more values related to the one ormore sensed parameters (as discussed further below) to a thresholdparameter to determine one or more valve conditions. If one or morevalve conditions have been determined, the valve controller 26 may beconfigured to send information that may be related to the one or moredetermined valve conditions from valve assembly 10 to the combustionappliance controller 60 (or other controller or device) across acommunication link or bus 100 connected to a communications interface110.

In one example, upon receiving one or more determined valve conditions,such as a safety event condition, the combustion appliance controller 60(or other controller or device) may be configured to open the safetyswitch 70, such that power to a valve control signal that is coupled toone or more valve actuators 30 is cut, thereby automatically closing oneor more valve ports 20 (e.g., closing valve sealing member(s) 22 ofvalve port(s) 20). In some cases, the safety switch 70 may be controlledby an algorithm in the combustion appliance controller 60, where anoutput of the algorithm is affected by information passed via thecommunication link 100. Additionally, or in the alternative, otherfeedback signals may affect an output of the algorithm, where the otherfeedback signals may or may not be passed via the communication link 100and may or may not originate from the valve assembly 10.

In other illustrative operations, a low gas pressure/high gas pressureevent may be reported from the valve controller 26 to the combustionappliance controller 60. In response to receiving a reported low gaspressure/high gas pressure event, the combustion appliance controller 60may be configured to open the safety switch 70. Further, in cases wherea proof of closure event is reported to the combustion appliancecontroller 60 prior to ignition of the combustion appliance, an ignitionsequence may not be started. In certain other instances where a ValveProving System (VPS) sequence test is being performed, a combustionappliance controller 60 may use reported results of the VPS sequencetest to make an evaluation. For example, if in the evaluation of the VPStest it were determined that a valve was leaking, the appliancecontroller 60 might be programmed to open safety switch 70, to initiatea safety lockout, to initiate an alarm, and/or to take any other similaror dissimilar measure.

In other scenarios, the valve assembly 10 may be used as a control valveand in that case, the valve controller 26 may send a signal to thecombustion appliance controller 60 indicative of a valve position, andthe combustion appliance controller 60 may respond accordingly. Theseother scenarios, for example, may be applied in parallel positioningsystem applications, low fire switch applications, auxiliary switchapplications, etc. Additionally, it is contemplated that the valvecontroller 26 may interact with remote devices in other similar anddissimilar manners within the spirit of this disclosure.

The pressure block or pressure sensor assembly 24 may be included in theflow module 28, as seen in FIGS. 9 and 10, and/or the pressure sensorassembly 24 may be at least partially separate from the flow module 28.The pressure sensor assembly 24 may be configured to continuously ornon-continuously sense pressure or a measure related to pressureupstream and/or downstream of a characterized port and/or along otherportions of the fluid channel 18. Although the pressure sensor assembly24 may additionally, or alternatively, include a mass or volume flowmeter to measure a flow of fluid through the fluid channel 18, it hasbeen contemplated that such meters may be more expensive and difficultto place within or outside the valve assembly 10; thus, a useful,relatively low cost alternative and/or additional solution may includeplacing the pressure sensors 38, 42, 43, 44 and/or other pressuresensors within, about and/or integrated in the valve body 12 of thevalve assembly 10 to measure the fluid flow through the fluid channel18, the pressures at the input and output ports, and/or other similar ordifferent pressure related measures. The pressure sensors 38, 42, 43, 44may include any type of pressure sensor element. For example, thepressure sensor element(s) may be MEMS (Micro Electro MechanicalSystems) pressure sensors elements or other similar or differentpressure sensor elements such as an absolute pressure sense element, agauge pressure sense element, or other pressure sense element asdesired. Example sense elements may include, but are not limited to,those described in U.S. Pat. Nos. 7,503,221; 7,493,822; 7,216,547;7,082,835; 6,923,069; 6,877,380, and U.S. patent applicationpublications: 2010/0180688; 2010/0064818; 2010/00184324; 2007/0095144;and 2003/0167851, all of which are hereby incorporated by reference.

In some cases, the pressure sensor assembly 24 may include adifferential pressure sensor 38 for measuring a differential pressuredrop across a characterized valve port 20, or across a differentcharacterized port, as seen in FIG. 9. A pressure sensor assembly 24including a differential pressure sensor 38, may be exposed to both afirst pressure 38 a upstream of a characterized valve port and a secondpressure 38 b downstream of the characterized valve port. Thedifferential pressure sensor 38 may send a measure related to the senseddifferential pressure to the microcontroller 36 of the valve controller26, as seen from the diagram of FIG. 9. The microcontroller 36 may beconfigured to monitor the differential pressure across the characterizedport with the differential pressure measures sensed by the differentialpressure sensor 38.

Alternatively, or in addition, an illustrative pressure sensor assembly24 may include one or more first pressure sensors 42 upstream of acharacterized valve port and one or more second pressure sensors 43downstream of the characterized valve port, where the first and secondpressure sensors 42, 43 may be in fluid communication with the fluidchannel 18 and may be configured to sense one or more measures relatedto a pressure upstream and a pressure downstream, respectively, of thecharacterized valve port, as seen in FIG. 10. Where a second valve port(e.g., the second valve port 20 b) may be positioned downstream of afirst characterized valve port (e.g. the first valve port 20 a) andforming an intermediate volume 19 between the first and second valveports, the pressure sensor assembly 24 may include one or more thirdpressure sensors 44 in fluid communication with the intermediate volume19, which may sense one or more measures related to a pressure in theintermediate volume 19. Where two characterized ports are utilized, thefirst pressure sensors 42 may be upstream of both characterized ports,second pressure sensors 43 may be downstream of both characterizedports, and the third pressure sensors 44 may be downstream from thefirst characterized port and upstream from the second characterized, butthis is not required (e.g., first and second pressure sensors 42, 43 maybe used to estimate the pressure drop across the valves). Additionally,or in the alternative, one or more differential pressure sensors 38 maybe utilized to estimate the pressure drop across the first characterizedport and/or the second characterized port. It is further contemplatedthat valve ports 20 may not be characterized ports.

The pressure sensors 42, 43, 44 may be configured to send each of thesensed measure(s) directly to the microcontroller 36. Themicrocontroller 36 may be configured to save the sensed measures and/orrelated information to the memory 37 (e.g., non-volatile memory or othermemory), and may perform one or more analyses on the received sensedmeasures. For example, the microcontroller 36, which may be a portion ofthe flow module 28 and/or the valve controller 26, may determine ameasure that is related to a fluid flow rate through the fluid pathbased, at least in part, on the received sensed measures related topressure upstream of the characterized port and on the received sensedmeasures related to pressure downstream of the characterized port.

Where a valve assembly 10 includes one or more valve ports 20, thepressure sensor assembly 24 may include the first pressure sensor 42positioned upstream of the first valve port 20 a at or downstream of theinlet port 14, as seen in FIG. 11. In addition, or alternatively, thepressure sensor assembly 24 may include a second pressure sensor 43positioned downstream of the second valve port 20 b at or upstream fromthe outlet port 16. The valve assembly 10 may further include one ormore third pressure sensors 44 downstream of the first valve port 20 aand upstream of the second valve port 20 b. The pressure sensors 42, 43,44 may be configured to sense a pressure and/or a measure related to thepressure in the fluid channel 18, and to communicate the sensed measuresto the valve controller 26, which is physically coupled to or positionedwithin the valve body 12. Where multiple pressure sensors 42, 43, 44exist at or near one or more location (e.g., upstream of the valve ports20, intermediate of the valve ports 20, downstream of the valve ports20, etc.) along the fluid channel 18, at least one of the multiplepressure sensors may be configured to sense pressures over a pressuresub-range different from a sub-range over which at least one other ofthe multiple pressure sensors at the location may be configured to sensepressure, but this is not required. In some cases, and as shown in FIG.8, the various pressure sensors may be mounted directly to acorresponding circuit board, such that when the circuit board is mountedto the valve body 12, the pressure sensor is in fluid communication witha corresponding fluid port in the valve body 12.

In some instances, such arrangements of pressure sensors 38, 42, 43, 44within valve assembly 10, along with the connection between the valvecontroller 26 and the pressure sensors 38, 42, 43, 44 may be used toemulate functions of high gas pressure (HGP) and low gas pressure (LGP)switches, which traditionally require wires and further housingsextending to and from and/or attached to the valve body 12. When theelectronics and elements of the valve assembly 10 are configured toemulate LGP/HGP switches, gas-valve wiring connections and interactionsmay be at least partially avoided, eliminated or simplified. In someinstances, such configuration of the valve controller 26 and thepressure sensors 38, 42, 43, 44 may reduce manual operations (e.g.,manually adjusting a mechanical spring or other device of conventionalhigh gas pressure (HGP) and low gas pressure (LGP) switches), and allowfor a more precise fitting with the electronics of the valve assembly10.

In some cases, the pressure sensor assembly 24 may include one or moreabsolute pressure sensors 54 in communication with the microcontroller36. The absolute pressure sensor 54 may sense an atmospheric pressureadjacent the gas valve assembly 10, and may be configured to communicateand transfer data related to the sensed atmospheric pressure to themicrocontroller 36. The microcontroller 36 may take into account theatmospheric pressure from the absolute pressure sensor 54 whendetermining the flow rate of fluid flowing through the characterizedport and/or an estimate of fuel consumption by an attached applianceand/or when determining threshold values. Other sensors may be includedin valve assembly 10, for example, one other type of sensor may be abarometric pressure sensor.

As discussed, the valve assembly 10 and the flow module 28 thereof mayinclude temperature sensor(s) 34, as seen in FIGS. 9-11. The temperaturesensor 34 may be positioned within the valve body 12 so as to be atleast partially exposed to the fluid channel 18 and configured to sensea temperature of a fluid (e.g., gas or liquid) flowing through the fluidchannel 18 and/or any other temperature in the fluid channel 18. Thetemperature sensor 34 may have a first temperature sensor 34 a at leastpartially exposed to the fluid channel 18 upstream of a characterizedvalve port, and/or a second temperature sensor 34 b at least partiallyexposed to the fluid channel 18 downstream of the characterized valveport, as seen in FIGS. 9 and 10. When there is a first valve port and asecond valve port (e.g., valve ports 20 a, 20 b), there may be a thirdtemperature sensor 34 c in fluid communication with intermediate volume19 between the first and second characterized valve ports, if desired.The sensed temperature measure may be used by flow module 28 to, forexample, compensate, correct, or modify a determined measure (e.g., adensity of a fluid) that is related to, for example, a fluid flow rateof fluid flowing through the fluid channel 18, which may help improvethe accuracy of the flow rate calculation. In operation, the temperaturesensor 34 (e.g., any or all of temperatures sensors 34 a, 34 b, 34 c)may communicate a sensed temperature measure directly or indirectly tothe valve controller 26 and/or the memory 37 (e.g., non-volatile memoryor other memory) of the valve controller 26 (e.g., the memory in amicrocontroller 36 or memory in another location) and/or the flow module28. The valve controller 26 may, in turn, utilize the sensed temperatureto help increase the accuracy of a determined flow rate of fluid passingthrough a characterized port and/or increase the accuracy of acalculated fluid and/or fuel consumption quantity, as desired, and storethe calculated flow rate of fluid passing through a characterized portand/or the calculated fluid and/or fuel consumption quantity in thememory 37 (e.g., non-volatile memory or other memory). Additionally, orin the alternative, in some instances the pressure sensors 38, 42, 43,44 may utilize built-in temperature sensors that are used to internallycompensate the pressure sensor over the operating temperature range. Insuch instances, the temperature reading may be accessible at thepressure sensor output (e.g., a digital communication bus) or at anotherlocation.

The flow module 28 of valve assembly 10 may further include a positionsensor system that may be configured to continuously or discontinuouslysense at least one or more of an axial position, a rotary position,and/or a radial position, of the valve sealing member 22 within or aboutthe fluid valve port 20. In some cases, the position sensor system mayinclude more than one position sensors 48, such that each positionsensor 48 may monitor a sub-range of a valve's total travel. Moreover,the position sensor system may be utilized as a proof of closure switchsystem. The position sensor(s) 48 of the position sensor system may besituated or positioned in valve body 12 at or about a valve port 20. Forexample, and in some instances, the position sensor(s) 48 may be fluidlyisolated from the fluid channel 18 (e.g., fluidly isolated from thefluid channel 18 by the valve body 12), and radially spaced from an axisupon which a valve sealing member(s) 22 may axially and/or rotationallytranslate between a closed position and an open position, as seen inFIGS. 14-17.

An illustrative gas valve assembly 10 may include a first valve port 20a and a second valve port 20 b (see FIG. 7), and a first position sensor48 a monitoring the first valve sealing member 22 a and a secondposition sensor 48 b monitoring the second valve sealing member 22 b,where the position sensors 48 a, 48 b may be separate devices or mayshare an enclosure and/or other parts. In the illustrative instance, thefirst position sensor 48 a may be fluidly isolated from the fluidchannel 18 and radially spaced from a first axis of the first valve port20 a, and the second position sensor 48 b may be fluidly isolated fromthe fluid channel 18 and radially spaced from a second axis of secondvalve port 20 b (see FIGS. 14-17).

As discussed above, the position sensor 48 may be configured to detect ameasure that is related to whether the valve sealing member 22 is in anopen or closed position and/or a measure related to an intermediateposition of the valve sealing member 22 within the fluid valve port 20.In one example, the position sensor(s) 48 may be configured to provide aproof of closure (POC) sensor(s) for the valve port(s) 20 (e.g., thefirst valve port 20 a and/or the second valve port 20 b).

Where the valve sealing member(s) 22 have a range of travel (e.g.,rotationally and/or axially) within the valve port(s) 20, the positionsensor(s) 48 may be configured to sense a current position of the valvesealing member(s) 22 anywhere along the range of travel of the valvesealing member(s) 22. The position sensor 48 may then send (e.g.,through electronic or other communication) sensed positioning data ofthe measure related to the position of the valve sealing member 22 tothe determining block and/or microcontroller 36 and/or the memory 37(e.g., non-volatile memory or other memory) of the valve controller 26and/or the flow module 28, where the microcontroller 36 may beconfigured to monitor the axial position of the valve sealing member 22within the valve port 20 through the position sensor system 48.

In some instances, the valve controller 26 may include an electroniccircuit board and/or a wired or wireless communication link 100 mayfacilitate communication between the position sensor(s) 48 and theelectronic circuit board or other device of the valve controller 26. Thevalve controller 26 may be configured to further pass on positioninginformation to remote devices through communication lines (e.g., thecommunication link 100) and/or display positioning data of the valvesealing member 22 on one or more displays 76 attached to the valveassembly 10 and/or the remote devices, as seen in FIG. 13. The valvecontroller 26 may indicate a closed or open position of the valvesealing member 22 or a degree (e.g., 10%, 20%, 30%, etc.) of an openingof the valve sealing member 22 with one or more visual indicators on orcomprising the display(s) 76, as seen in FIG. 13, such as one or morelight emitting diodes (LEDs) acting as a visual indication of a valvestate and/or position, liquid crystal displays (LCDs), a touch screen,other user interfaces and/or any other display interfacing with ordisplaying information to a user.

In some instances, the position sensor system may include one or moreswitches 64 (e.g., a first switch 64 a and a second switch 64 b, wherethe switch(es) 64 may be or may include relays or other switch typessuch as FETs, TRIACS, etc.) having one or more switched signal paths 66and one or more control inputs 68 (e.g., a first control input 68 a anda second control input 68 b), as seen in FIG. 13. Illustratively, oneswitch 64 may be utilized for multiple position sensors 48, or more thanone switch 64 may be utilized for multiple position sensors (e.g., in a1-1 manner or other manner), as desired. The control input 68 may setthe state of the switched signal paths 66 to a first state or a secondstate or another state, as desired. As depicted in FIG. 13, the valvecontroller 26 may be coupled to the position sensor(s) 48, and maycontrol input 68 of switch 64, where both the valve controller 26 andthe position sensors 48 may be isolated from fluid communication withthe fluid channel 18. In some instances, the valve controller 26 may beconfigured to set the state of the switched signal path 66 to the firststate when the first position sensor 48 a senses that a first valve port20 a is not closed or the first valve sealing member 22 a is not in aclosed position, and to a second state when position sensor 48 sensesthat a first valve port 20 a is closed or the first valve sealing member22 a is in a closed position. Similarly, the valve controller 26 may beconfigured to set the state of the switched signal path 66 to the firststate when the second sensor 48 b senses that the second valve port 20 bis not closed or the second valve sealing member 22 b is not in a closedposition, and to a second state when the position sensor 48 senses thata second valve port 20 b is closed or the second valve sealing member 22b is in a closed position. In the alternative, the valve controller 26may be configured to set the state of the switched signal path 66 to thefirst state when at least one of the first and second sensors valveports 20 a, 20 b are not closed or at least one of the first and secondvalve sealing members 22 a, 22 b are not in a closed position, and to asecond state when the position sensor 48 senses that both first andsecond valve ports 20 a, 20 b are closed or both the first and secondvalve sealing members 22 a, 22 b are in closed positions. Similar oridentical or different processes, as desired, may be utilized for eachposition switch 64 and control input 68.

Illustratively, the valve sealing member(s) 22 may include a sensorelement 80, and position sensor(s) 48 may include one or more transduceror field sensors 82. For example, valve sealing member(s) 22 may includea sensor element 80 (e.g., a magnet when using a field sensor 82, aferrous core when using a linear variable differential transformer(LVDT) 84, or other sense element, and/or similar or dissimilarindicators) secured relative to and translatable with valve sealingmember(s) 22. Position sensor(s) 48 may include one or more fieldsensors 82 (e.g., magnetic field sensors, a LVDT 84, Hall Effect sensorsor other similar or dissimilar sensors), as seen in FIGS. 14-15. Fieldsensor 82 may be positioned within valve body 12 or may be positionedexterior to valve body 12 and radially spaced from a longitudinal axisof the valve port(s) 20 and/or the valve sealing member(s) 22. Theposition sensor(s) 48 may be positioned so as to be entirely exterior tothe fluid channel 18. The meaning of entirely exterior of the fluidchannel 18 may include all position sensors 48 and all electronics(e.g., wires, circuit boards) connected to the position sensor(s) 48being exterior to fluid channel 18. Where the position sensor(s) 48includes an LVDT, the LVDT may be positioned concentrically around andradially spaced from the valve sealing member(s) 22, as shown in FIG.15, and/or the axis of LVDT may be spaced radially and parallel from thevalve sealing members 22.

In some cases, a strain gauge 86, as depicted in FIG. 16, or otherelectromechanical sensor may also be utilized to sense a position of thevalve sealing member 22 within an interior of the fluid channel 18 froma position fluidly exterior of the fluid channel 18 by sensing a strainlevel applied by the spring 31 in communication with valve sealingmember 22. Alternatively, or in addition, the valve sealing member(s) 22may include one or more visual indicators 88 (e.g., a light reflector orother visual indicators), and the position sensor(s) 48 may include oneor more optical sensors 90, as seen in FIG. 17, where visual indicatorsmay be any indicators configured to be viewed by optical sensors througha transparent window 87 sealed with an o-ring or seal 89 or throughanother configuration, such that optical sensors 90 may determine atleast whether the valve sealing member(s) 22 is/are in a closed or openposition. Where a visual position indicator 88 is utilized, and in somecases, a user may be able to visually determine when the valve sealingmember(s) 22 is not in a closed position.

As may be inferred from the disclosure, the position sensor 48 may insome instances operate by detecting a position of a valve sealing member22 and/or optionally the valve stem 92 or the like within a valveassembly 10 having a valve body 12, where the valve sealing member 22may be translatable with respect to the valve port 20 of the valve body12 along a translation or longitudinal axis “A” within a valve port 20.In some cases, the sensor element 80, affixed relative to the valvesealing member 22, may be positioned within the interior of the valvebody 12 and may optionally fluidly communicate with the fluid channel18; however, the position sensor 48 may be isolated from the fluidchannel 18 and/or positioned exterior to the valve body 12. In anillustrative embodiment, the valve sealing member 22 may be positionedat a first position within an interior of the valve port 20 alongtranslation axis A. The first position of the valve sealing member 22may be sensed with position sensor 48 by sensing a location of a sensorelement 80 secured relative to the valve sealing member 22 with theposition sensor 48. Then, the position sensor 48 may automatically orupon request and/or continuously or discontinuously, send the sensedlocation and/or open or closed state of the valve sealing member 22 tothe valve controller 26.

It is contemplated that the valve controller 26 may electronicallycalibrate the closed position of the valve sealing member 22 and/or thevalve stem 92. Such a calibration may store the position of the valvesealing member 22 and/or the valve stem 92 when the valve sealing member22 and/or the valve stem 92 is in a known closed position (e.g. such asduring installation of the valve assembly 10). During subsequentoperation, the position of the valve sealing member 22 and/or the valvestem 92 can be compared to the stored position to determine if the valvesealing member 22 and/or the valve stem 92 is in the closed position. Asimilar approach may be used to electronically calibrate other positionsof the valve sealing member 22 and/or the valve stem 92 (e.g. fully openposition, or some intermediate position), as desired.

As discussed, the valve controller 26 may be configured to determine oneor more valve conditions and/or valve related events based on one ormore diagnostic parameters related to the fluid channel 18 sensed by oneor more sensor(s) (e.g., a pressure sensor, etc.) in communication withthe fluid channel 18. The diagnostic parameters may be determined by thevalve controller 26 and stored in the memory 37 (e.g., non-volatilememory) or other memory accessible by the valve controller 26. Thediagnostic parameters may include, but are not limited to, a totalnumber of operational cycles, a fuel usage parameter, one or more faulthistory parameters, one or more user or factory or other settingparameters, self-diagnostic check parameters, totalized repositioning,gas pressure, temperature pressure, leakage level detection during ValveProving Systems, fault parameters, and/or other similar or dissimilarparameters, as desired. The communicated valve condition(s) ormeasure(s) related to the valve condition(s) may be determined by valvecontroller 26 or one or more remote devices. Illustrative valveconditions and measures related to valve conditions may include, but arenot limited to: high fuel pressure conditions, low fuel pressureconditions, valve closure conditions, valve leak conditions, safetyevent conditions, and/or other similar or dissimilar valve conditionsand/or outputs.

The valve controller 26 may determine one or more valve conditions basedon one or more sensed parameters (e.g., sensed diagnostic parameters) bycomparing values related to the one or more sensed parameters (e.g.,values related to sensed parameters of the local sensors and/or valuesrelated to sensed parameters from one or more remotely located sensors)to threshold values. Values related to the one or more sensed parametersmay include values of the sensed parameters and/or values derived,calculated, and/or determined from one or more of the values of thesensed parameters. In some illustrative instances, values related to theone or more sensed parameters may include the values resulting frommathematically processing one or more values of the one or more sensedparameters. In one example, one or more values of one or more sensedparameters may be inserted into an equation and the result of theequation after inserting the one or more values therein may be the valuerelated to the one or more sensed parameters. Illustratively, values ofone or more sensed parameter may be processed to combine outputs (e.g.,values) from a plurality of sensors, to combine outputs from one or moresensors over time, to filter outputs from one or more sensors over timeto reduce noise, to reduce offset error, to reduce gain error, toconvert values to a different unit, and/or to process values of sensedparameters in one or more other manners.

In some cases, the memory 37 may store two or more selectable optionsselectable through a user interface 73 or other mechanism, where eachselectable option identifies corresponding threshold values for the oneor more threshold values. The threshold values stored in the memory 37may include one or more adjustable threshold values and/or one or morefixed threshold values, where the adjustable threshold values may beadjustable by a user in the field and the fixed threshold values are notadjustable by a user in the field.

In some instances, the user interface 73 (e.g., display 52, display 62,display 76, and/or one or more other displays 77) of or in communicationwith the valve assembly 10, as shown in FIG. 11, may be configured toreceive a selection from a user of one of the two or more selectableoptions stored in the memory 37 or other memory of or in communicationwith the valve assembly 10, and/or receive, accept, and save a thresholdvalue related to a sensed parameter. In one example of a selection oftwo or more selectable options, a user may select a safety standardoption from a menu and software (e.g., stored in the memory 37 or othermemory in communication with the valve controller) of the valvecontroller 26 may identify threshold values associated with the selectedselectable option that relate to the sensed parameters. Once one or moreof the selectable options is/are selected and/or one or more thresholdvalues are accepted by the user interface, the valve controller 26 mayuse the one or more threshold values that correspond to the selectedselectable option(s) when comparing values related to the one or moresensed parameters to the one or more threshold value(s) to determine oneor more valve conditions.

In some instances, each of the two or more selectable options stored inthe memory 37 or other memory may correspond to a different safetystandard that may be selectable by a user. Each of, or one or more of,the selectable options stored in the memory 37 or other memory may be asafety standard of a safety agency, a regional safety standard, acountry safety standard, or any other safety standard.

The user interface 73 may include or may be a display with a touchscreen, a key pad, selectable buttons, biometric scanners, and/or otherfeatures that facilitate two-way communication, where the display may bemechanically secured relative to the valve body 12, may be a displaywired to the valve controller 26 or the microcontroller 36 of the valvecontroller 26, may be a mobile computing device, may be a personalcomputer, and/or any combination thereof. As discussed, the userinterface 73 may be configured to receive a selection of selectableoptions (e.g., options stored in memory of the valve assembly 10 orother memory) and/or receive input from users in one or other manners.Illustratively, the user interface 73 may receive and/or accept inputsuch as selections of selectable options; threshold values for the valvecontroller 26 to utilize when comparing sensed parameters to thresholdvalues; passwords required before a user is allowed to select one ormore selectable options, access data of the valve assembly, and/or enterone or more parameter related inputs; biometric information (e.g., aretina pattern of a user, a fingerprint, etc.), and/or other inputs.

Safety standards may require that settings of components in a systemutilizing fuel safety shut off valves, as in some embodiments of valveassembly 10, to be protected against tampering and/or accidental changein the field. Some of the components having settings that may need to beprotected from tampering and/or accidental change include, but are notlimited to, proof of closure contacts, low and high gas pressureswitches, valve proving switches, opening and/or closing profiles,fuel-to-air ratios, regulator output pressure sensors, cycle counters,and/or other components. Some tamper preventing mechanisms may includetamper resistant caps and/or covers, along with locks or othermechanical tools. These tamper preventing mechanisms may require specialtools to perform field adjustments to the systems utilizing safety shutoff valves and thus may be difficult to interact with due to spaceconstraints, lack of lighting, and other considerations. Additionally,when mechanical tamper preventing mechanisms are used, it may bedifficult to track/log changes to the system, and establishing settingsfor the system from a remote location may not be possible.

In some cases, all or substantially all mechanical manners of tamperingresistance may be eliminated if all mechanical system adjustmentmechanisms (e.g., a set screw, potentiometer, or other mechanicallyadjustable mechanism) are replaced by or substituted with an electronicmechanism. By utilizing a two-way user interface 73 (e.g., a userinterface that accepts input and provides output), mechanical tamperpreventing mechanism may be avoided. Instead, users may enter a passwordor provide other identity authorization (e.g., biometrics, sense elementkeys/tools, etc.) through the user interface 73 or other electronicaccess mechanisms to gain access to data and/or settings stored on or atelectronics on the valve body 12.

When system settings and/or data of the system are electronicallypassword protected or protected in any other electronic manner, a userinterface 73 (e.g., a local display or a remote display) incommunication with the valve assembly 10 may be utilized to enter apassword and access system settings and/or data. As discussed above,illustrative user interfaces may be one or more of the display 76 on thecontroller, a system display 52, an appliance display 62, and/or otherdisplay 77 (e.g., a remote display, such as a mobile devices or personalcomputer). The user interface 73 may be in communication with the valveassembly 10 via a communication interface 110 with a wired or wirelesscommunication link 100, and once a password is entered, system data maybe accessed and/or system settings may be applied at the user interface73.

In some instances, in addition or as an alternative to using a password,an electronic access tool or key 79 (e.g., a tool or key with an RFIDtag, sense element, or other Near Field Communication (NFC) technology)or a button on the valve assembly 10 (e.g., a reset button utilized toleave a lockout mode or other button) may be utilized to access valveassembly system settings. The electronic tool or key 79 may be sensed bythe valve assembly and whoever is holding or in possession of the sensedelectronic tool or key 79 may be authorized to do field adjustments tothe system settings and/or view data of the valve assembly 10.

In some instances, the button on the valve assembly 10 and/or theelectronic access tool or key 79 may be utilized as a proximityauthentication tool in combination with a password to furtherauthenticate a user attempting to gain access to system settings and/ordata of the valve assembly 10 by requiring the user to be in physicalproximity to the valve assembly 10 around the time of entering apassword. In one example, a user may be required to press the button onthe valve assembly 10 or have the electronic access tool or key 79adjacent the valve assembly 10 before, during, and/or after entering apassword (e.g., during a time window with respect to when a password isentered). Such a utilization of a password and a proximityauthentication tool may facilitate preventing unauthorized users fromaccessing the system settings and/or data of the valve assembly 10 if apassword has been stolen, leaked and/or otherwise compromised, thecommunication link 100 has been hacked and/or compromised, and/or inother instances of when an unauthorized user may attempt to access thesystems and/or data of the valve assembly 10.

To increase tampering resistance and/or to prevent accidental changes insettings, the valve controller 26 or other portion of the valve orappliance system may disable the ability to adjust settings and/or viewdata after a predetermined amount of time of inactivity after a user islogged in and/or after a predetermined amount of time after a user islogged in. In one example, the valve controller 26 may disable theability to adjust settings and/or view valve data after one (1) minute,after two (2) minutes, after three (3) minutes or other period ofinactivity of a logged in user and/or after ten (10) minutes, twenty(20) minutes, thirty (30) minutes or other period after a user lastlogged in. Additionally or alternatively, the valve controller 26 maydisable the ability to adjust settings after a predetermined number offailed access tries (e.g., a predetermined number incorrect passwordentries). When an electronic access tool or key 79 is used to log intothe valve controller 26 to view/change settings and/or view data, theability to adjust settings and/or view data may be disabled when theelectronic access tool or key 79 is separated from the valve assembly 10by a predetermined distance (e.g., five (5) feet, ten (10) feet, twenty(20) feet, one hundred (100) feet, and so on).

The user interface and/or the valve assembly 10 may time stamp allaccess to the valve assembly 10 settings and/or data, along withrecording some or all actions taken after access is granted. Suchrecorded time stamps and actions taken may be stored in the memory 37(e.g., non-volatile memory or other memory) of the valve controller 26.In some instances, an administrator or administrator account may benotified of all valve assembly system changes, where the administratoror administrator account receives notification on a remote display orother user interface connected via a communication link to the valvecontroller 26 of the valve assembly 10.

In some instances, users using passwords and/or electronic access toolsor keys 79 to access the valve controller 26 may have different levelsof authorization based on profiles associated with the utilized passwordand/or electronic access tool or key 79. Such authorization levels maydelineate which users are allowed to adjust which settings and/or viewwhich data. For example, users at a first level may be allowed to adjusta value within a predefined set of limits and users at a second levelmay be allowed to adjust a value within a predetermined set of limitsand may also have the authorization to modify the predetermined setlimits. In some cases, a user's password indicates to the valvecontroller 26 for what level of access a user is authorized.

The valve controller 26 may be configured to provide a warning inresponse to determining that one or more sensed parameters meet and/orexceed one or more threshold values (e.g., the threshold values enteredby a user, related to an option selected by a user, and/or one or moreother threshold values). Additionally or alternatively, the valvecontroller 26 may be configured to provide a warning in response toidentifying a trend identified among a plurality of sensed parametersover time (e.g., a predetermined time, a time selected by a user duringa process, etc.). For example, if the valve controller 26 determinesthat a failure is expected to occur or that the valve will fall out ofspec, the valve controller may issue a warning to the user. This warningmay indicate that the valve assembly can still be safely operated butwill need maintenance or replacement soon. In some cases, the valvecontroller 26 may predict the expected remaining life of the valveassembly, and may report the expected remaining life to the user.

In some cases, the valve controller 26 may provide a warning if itidentifies two sensed parameters that each meet and/or exceed acorresponding sub-threshold value (e.g., sub-threshold values may beless than the threshold values). For example, if the current draw toactuate the valve controller is found to exceed a first sub-threshold,and a time to move the valve between the open and closed position isfound to exceed a second sub-threshold, the valve controller 26 mayprovide a warning. This warning may indicate that the valve assembly canstill be safely operated but will need maintenance or replacement soon.In some cases, two or more sensed parameters may be combined (e.g. via afunction, equation or the like) to provide a combined parameter. It maybe determined if the combined parameter meets and/or exceeds one or morethreshold values or sub-threshold values. In one example, hightemperature can often shorten electrical component and/or mechanicalcomponent life. As such, a sensed temperature over time may beintegrated with the total run time of the valve assembly to provide atemperature lifetime parameter. The valve controller 26 may issue awarning if the temperature lifetime parameter meets and/or exceeds atemperature lifetime threshold value or sub-threshold value. In somecases, the valve controller 26 may predict an expected remaining life ofthe valve assembly based on the temperature lifetime parameter. Theseare just some examples.

A warning may be provided through the user interface 73 in response toreceiving a warning signal (e.g., a warning signal from themicrocontroller 36 of the valve controller 26). In one example ofdisplaying a warning, the user interface may display a suggested rootcause of the warning signal when displaying the warning signal, awarning light, a description of the warning, a parameter associated withthe warning, a suggested fix to the issue causing a warning, steps totake in response to a warning, and/or other measures related to awarnings.

In some cases, the valve controller 26 may be configured to provide asingle level warning or an escalating level of warnings in response todetermining that one or more sensed parameters are approaching, meet,and/or exceed one or more of the threshold values. When the valvecontroller 26 is configured to provide escalating levels of warnings, afirst warning signal indicating a first warning level may be providedwhen a sensed parameter meets and/or exceeds a first threshold value,and a second warning signal indicating a second, higher warning levelmay be provided when the sensed parameter meets and/or exceeds athreshold value. Additionally, or alternatively, when the valvecontroller 26 is configured to provide escalating levels of warnings, afirst warning signal indicating a first warning level may be providedwhen a first sensed parameter meets and/or exceeds a threshold value,and a second warning signal indicating a second warning level may beprovided when a second sensed parameter meets and/or exceeds a thresholdvalue.

In some cases, the valve controller 26 may be configured to take one ormore actions as part of or in addition to providing a warning signalwhen a sensed parameter value meets and/or exceeds a threshold value. Inone example, the valve controller 26 may take an action by shutting downthe valve assembly 10 if one or more of the sensed parameters meetand/or exceed one or more of the fixed thresholds (e.g., a threshold setby a safety standard or regulation or a threshold set in a differentmanner). Additionally or alternatively, the action the valve controller26 may be to allow the valve assembly 10 to continue to operate butissue an alert or a particular level of warning if one or more sensedparameter meets and/or exceeds one or more of the adjustable thresholds(e.g., a threshold set by a user as an indication a parameter may beapproaching a fixed threshold or a threshold set in a different manner).

In an illustrative method of operating the valve assembly 10, the valveassembly may receive at the user interface 73 input relating to aselection and/or entering of one or more safety standards saved in thememory (e.g., memory 37) of the valve assembly 10, where each of thesafety standards includes one or more threshold values related toparameters sensed the by local and/or remote sensors. With the localand/or remote sensors, one or more parameters may be sensed and valuesof those sensed parameters may be obtained and transferred to the valvecontroller 26 of the valve assembly 10. The valve controller 26 may beutilized to determine one or more valve conditions and/or valve eventsbased on the one or more sensed parameters and the one or morethresholds designated by the selected and/or entered safety standard. Anindication of the determined one or more valve conditions may bedisplayed on the user interface 73 (e.g., one or more of display 52,display 62, display 76, and display 77).

Those skilled in the art will recognize that the present disclosure maybe manifested in a variety of forms other than the specific embodimentsdescribed and contemplated herein. Accordingly, departure in form anddetail may be made without departing from the scope and spirit of thepresent disclosure as described in the appended claims.

What is claimed is:
 1. A valve assembly comprising: a valve body havingan inlet port and an outlet port, with a fluid path extending betweenthe inlet port and the outlet port; a valve situated in the fluid pathbetween the inlet port and the outlet port; a valve actuator, securedrelative to the valve body, for selectively moving the valve between aclosed position, which closes the fluid path between the inlet port andthe outlet port, and an open position; one or more local sensors forsensing one or more local parameters of the valve, the valve actuator,and/or within the valve body; one or more remote sensor inputs forreceiving one or more remote parameters from one or more remotelylocated sensors, wherein the one or more remotely located sensors areoutside of and not integral with the valve body, the valve and the valveactuator, and the one or more remote parameters are not sensed in thefluid path of the valve body upstream or downstream of the valve; and acontroller secured relative to the valve body and in communication withthe plurality of local sensors and the one or more remote sensor inputs,the controller configured to determine one or more valve conditionsbased, at least in part, on a comparison of one or more values relatedto one or more of the remote parameters from the one or more remotelylocated sensors with one or more threshold values.
 2. The valve assemblyof claim 1, wherein the controller is configured to determine one ormore of the valve conditions based, at least in part, on a comparison ofone or more values related to one or more of the local parameters fromthe one or more local sensors and one or more threshold values.
 3. Thevalve assembly of claim 1, further comprising: a user interface incommunication with the controller of the valve assembly, the userinterface configured to receive user input related to the one or morethreshold values, and to provide an indicator related to the one or moredetermined valve conditions to a user.
 4. The valve assembly of claim 1,wherein the one or more local sensors include one or more of a pressuresensor, a flow sensor, a temperature sensor, a position sensor, and acurrent sensor.
 5. The valve assembly of claim 1, wherein the one ormore remotely located sensors include one or more of a pressure sensor,a flow sensor, a temperature sensor, a position sensor, a currentsensor, a gas sensor, an oxygen sensor, a CO sensor, and a CO₂ sensor.6. The valve assembly of claim 1, wherein the controller is configuredto identify one or more trends in one or more remote parameters over apredetermined time.
 7. The valve assembly of claim 6, wherein thecontroller is configured to identify a correlation between trends in twoor more remote parameters.
 8. A valve assembly system comprising: avalve assembly comprising: a valve body having an inlet port and anoutlet port, with a fluid path extending between the inlet port and theoutlet port; a valve situated in the fluid path between the inlet portand the outlet port; a valve actuator, secured relative to the valvebody, for selectively moving the valve between a closed position, whichcloses the fluid path between the inlet port and the outlet port, and anopen position; one or more sensors in communication with the fluid pathfor sensing one or more sensed parameters within the fluid path of thevalve body; a controller secured relative to the valve body and incommunication with the one or more sensors, the controller determiningone or more valve conditions based at least in part on the one or moresensed parameters by comparing values related to the one or more sensedparameters to corresponding ones of two or more threshold values; amemory secured relative to the valve body and operatively coupled to thecontroller, the memory storing two or more selectable options, whereineach selectable option identifies corresponding threshold values for thetwo or more threshold values, wherein one or more of the thresholdvalues is an adjustable threshold value that is adjustable by a user inthe field, and one or more of the threshold values is a fixed thresholdvalue that is not adjustable by a user in the field; and a userinterface configured to receive a selection from a user of one of thetwo or more selectable options stored in the memory, wherein onceselected, the controller is configured to use the two or more thresholdvalues that correspond to the selected selectable option when comparingvalues related to the one or more sensed parameters.
 9. The valveassembly system of claim 8, further comprising an electronic accessmechanism configured to restrict access to the selection of one of thetwo or more selectable options stored in the memory.
 10. The valveassembly of claim 9, wherein the electronic access mechanism includes apassword protection system and the user interface is configured toreceive a password prior to allowing the selection from a user of theone of the two or more selectable options stored in the memory.
 11. Thevalve assembly of claim 9, wherein the electronic access mechanismincludes a button on the valve assembly for selection to ensure userproximity to the valve assembly.
 12. The valve assembly of claim 9,wherein the electronic access mechanism includes a sense elementconfigured to be sensed by the valve assembly.
 13. The valve assemblysystem of claim 8, wherein the controller is configured to provide analert in response to determining that one or more sensed parameters goesbeyond one of the adjustable threshold values.
 14. The valve assemblysystem of claim 8, wherein the controller is configured to shut down thevalve in the closed position in response to determining that one or moreof the sensed parameters goes beyond a corresponding one of the one ormore fixed threshold values.
 15. The valve assembly system of claim 8,wherein the controller is configured to: provide an alert in response todetermining that one or more sensed parameters goes beyond one of theadjustable threshold values; and shut down the valve, in the closedposition, in response to determining that one or more of the sensedparameters goes beyond a corresponding one of the one or more fixedthreshold values.
 16. The valve assembly system of claim 8, wherein thecontroller is configured to: issue a first alert when a value related toa first sensed parameter goes beyond a first adjustable threshold value;and issuing a second alert when a value related to a second sensedparameter goes beyond a second adjustable threshold value.
 17. The valveassembly system of claim 8, wherein the valve assembly further comprisesone or more sensors inputs for receiving one or more remote parametersfrom one or more remotely located sensors, wherein the one or moreremotely located sensors are outside of and not integral with the valvebody, the valve and the valve actuator, and the one or more remoteparameters are not sensed in the fluid path of the valve body upstreamor downstream of the valve.
 18. A method of operating a valve assemblycomprising: receiving input related to a selection of one or more safetystandards via a user interface, wherein each safety standard designatestwo or more threshold values, wherein one or more of the thresholdvalues is an adjustable threshold value that is adjustable by a user inthe field, and one or more of the threshold values is a fixed thresholdvalue that is not adjustable by a user in the field; sensing one or moresensed parameters of the valve assembly; transferring values of the oneor more sensed parameters to a controller of the valve assembly; usingthe controller of the valve assembly to determine one or more valveconditions based on the one or more sensed parameters and the two ormore threshold values designated by the selected safety standard;displaying an indication of the one or more valve conditions on a userinterface; shutting down the valve assembly if a value related to one ormore of the sensed parameters goes beyond a corresponding one of the oneor more fixed threshold values; and allowing the valve assembly tooperate but issuing an alert if a value related to one or more sensedparameters goes beyond a corresponding one of the one or more adjustablethreshold values.
 19. The method of claim 18, further comprising:issuing a first alert when a value related to a first sensed parametergoes beyond a first adjustable threshold value; and issuing a secondalert when a value related to a second sensed parameter goes beyond asecond adjustable threshold value.
 20. The method of claim 19, whereinthe value related to the first sensed parameter is sensed by a localsensor sensing one or more local parameters within the valve assembly;and the value related to the second sensed parameter is sensed by aremote sensor sensing one or more remote parameters outside of the valveassembly.